Drill systems with coolant delivery arrangements and methods

ABSTRACT

There is provided a drill tool assembly for drilling metallic or other materials, comprising a holder having a mounting slot in which a cutting insert is positioned, and a through tool coolant supply system. The drilling tool system allows for the application of coolant to the rake surfaces of the cutting insert in a manner which facilitates enabling higher penetration rates while maintaining integrity of the cutting edges of the cutting insert. The drilling tool system comprises a holder having a rotational axis and mounting slot. A cutting insert with sides positioned adjacent the side surfaces of the mounting slot and cutting edges extending from the rotational axis is mounted in the slot. The insert includes rake surfaces adjacent the cutting edges that are positioned above the mounting slot. At least one coolant channel is disposed with at least one coolant outlet directed at the sides of the insert at a position below the rake surfaces. The coolant outlet is configured to disperse coolant in a curtain across the entire rake face of each cutting edge.

CROSS REFERENCE TO RELATING APPLICATIONS

This application is a continuation of co-pending U.S. application Ser.No. 16/850,684 filed on Apr. 16, 2020, issuing Feb. 28, 2023 at U.S.Pat. No. 11,590,587, which is incorporated by reference herein in itsentirety.

TECHNICAL FIELD

The present invention relates to a drill tool assembly for drillingmetallic or other materials, comprising a holder having a mounting slotin which a cutting insert is positioned, and a through tool coolantsupply system. More specifically, this invention relates to a drillingtool system that allows for the application of coolant to the rake faceof the cutting insert in a manner which facilitates enabling higherpenetration rates while maintaining integrity of the cutting edges ofthe cutting insert.

BACKGROUND OF THE INVENTION

In the metal cutting industry, it is highly desired to make use ofcoolant to achieve better tool performance. Using coolant provideslubricity, heat dissipation from the tool, and aids in chip evacuation.This results in a tool that can operate faster and achieve longer toollife. Though the use of coolant in drilling products to variousindustries is typical, a need still exists in the drilling tool industryfor a coolant delivery method that excels at targeting the interface ofthe chip and rake face of the cutting geometry, particularly in drillingtools with two effective cutting edges. The delivery of coolant in suchtools has not allowed for higher penetration rates to be achieved in thedrilling operation, without sacrifice of tool life. Achieving this iseven more critical because the properties of many materials beingdrilled today create undesirable heat, friction, and adhesion to therake face of drilling tools of this type, which negatively affect drillperformance. These undesirable effects are amplified by the increasingdesire to drill holes faster in high production environments. It istherefore clear that there is a significant need for coolant delivery ina manner which excels at reducing heat, friction, and adhesion on therake face during the drilling operation, allowing for enhancedperformance at speeds elevated over similar drill designs.

SUMMARY OF THE INVENTION

The invention is therefore directed to a drilling tool which achievesthe beneficial effects of minimizing undesirable heat, friction, andadhesion to the rake face of drilling tools of this type. The drillingtool system comprises a holder having a rotational axis and first andsecond clamp arms with side surfaces forming a mounting slot. A cuttinginsert with sides positioned adjacent the side surfaces of the mountingslot and cutting edges extending from the rotational axis is mounted inthe slot. The insert includes rake surfaces adjacent the cutting edgesthat are positioned above the first and second clamp arms when theinsert is mounted in the mounting slot. At least one coolant channel isdisposed through the first and second clamp arms with at least onecoolant outlet directed at the sides of the insert at a position belowthe rake surfaces. The coolant outlet is configured to disperse coolantin a curtain across the entire rake face of each cutting edge.

A drill tool assembly according to an example comprises a holder havingfirst and second ends and a rotational axis. The second end of theholder is configured to be fixedly attached in a drilling machine, andthe first end comprises a holder slot having a bottom seating surfaceover at least a portion of the holder slot. At least one cutting inserthaving first and second sides is provided, with the first sidepositioned in the holder slot in seating engagement with the bottomseating surface of the holder, such that the insert has a commonrotational axis with the holder. The second side of the insert includesfirst and second double effective cutting edges extending from therotational axis, and first and second rake faces adjacent the cuttingedges. The holder further includes at least first and second coolantholes extending through the holder and directing an amount of coolantonto the first and second rake faces at a predetermined location andvolume of coolant to spread out on the first and second rake faces oversubstantially the entire portion of the rake face adjacent each cuttingedge.

In an example, the drill tool assembly comprises at least first andsecond coolant holes extending through the holder and having an exitopening at least partially in the holder slot and angled to direct anamount of coolant onto the first and second rake faces at apredetermined location adjacent the holder slot and at an angle to therake face. In an example, the drill tool assembly comprises at leastfirst and second coolant holes extending through the holder and havingan exit opening in the holder slot and into at least one reservoiradjacent the rake face and direct an amount of coolant onto the firstand second rake faces at a predetermined location from the at least onereservoir.

The invention also provides a method of delivering coolant in a drillingoperation using a drilling tool comprising a holder having first andsecond ends and a rotational axis. The second end of the holder isconfigured to be fixedly attached in a drilling machine, and the firstend of the holder comprising a mounting slot with side surfaces and acutting insert positioned in the mounting slot with side surfacespositioned adjacent the side surfaces of the mounting slot, and whereinthe insert includes first and second double effective cutting edgesextending from the rotational axis, and first and second rake facesadjacent the cutting edges and above the mounting slot of the holder,and wherein the holder further includes at least first and secondcoolant outlets positioned adjacent the sides of the insert, anddirecting an amount of coolant under pressure onto the side surfaces ofthe insert to cause the dispersal of coolant in a curtain oversubstantially the entire portion of the rake surface adjacent eachcutting edge.

The coolant supply arrangement provides a constant directed coolantspray across the rake face of the cutting geometry, particularly acrossthe rake face of a double effective cutting edge arrangement. Typicaldrill designs do not target this critical cutting zone with directedcoolant, and instead rely on a flooding effect of coolant to attempt toreach this area. Additionally, the coolant delivery system in thedrilling tool of the invention aids in chip segmentation, throughthermal shocking of the chip at the rake face provided by the directedcoolant. The targeted coolant also improves lubricity and coolant flowaround the cutting area, minimizing re-cutting of chips and promotingsuperior chip evacuation from the drilled hole. It is also important tonote that this coolant delivery system and method can be used inconjunction with additional coolant outlets that are targeting othercritical areas of the cutting action within the same drill body. Suchadditional coolant supply may depend on various factors and depend onthe application and material.

Accordingly, this invention provides an improved drill tool assembly andmethod to enable minimization of undesirable heat, friction, andadhesion to the rake face of material during a drilling operation,resulting in the ability to operate the drilling tool at higher speedswhile providing exceptional tool life.

The above improvements and advantages along with other objects andadvantages of the present invention will become readily apparent from areading of the detailed description of various examples taken inconjunction with the drawings and the claims.

BRIEF DESCRIPTION OF THE DRAWINGS

The invention and characteristics thereof are described in more detailin the following by way of examples with reference to the drawings, inwhich:

FIG. 1 is a view of the drill tool holder body in an example.

FIG. 2 is a partial perspective view of the holder shown in FIG. 1 .

FIG. 3 is a view of cutting insert to be mounted in the holder of FIG. 1in the drill tool assembly.

FIG. 4 is a partial sectional view of the holder shown in FIG. 1 .

FIG. 5 is a partial sectional view of the holder shown in FIG. 1 , withthe insert of FIG. 2 mounted in association with the holder.

FIG. 6 is a partial perspective view of an alternative example of aholder in the drilling tool assembly of the invention.

FIG. 7 is a partial perspective view of the holder of FIG. 6 , with theinsert of FIG. 2 mounted in association with the holder.

FIG. 8 is a partial sectional view of the holder shown in FIG. 6 , withthe insert of FIG. 2 mounted in association with the holder.

FIG. 9 is a partial sectional view of the holder shown in FIG. 6 , withthe insert of FIG. 2 mounted in association with the holder.

FIG. 10 is a partial perspective view of an alternative example of aholder in the drilling tool assembly of the invention.

FIG. 11 is a view of an alternative example of a cutting insert in thedrilling tool assembly of the invention.

FIG. 12 is a partial sectional view of the holder shown in FIG. 10 ,with the insert of FIG. 11 mounted in association with the holder.

FIG. 13 is a partial perspective view of an alternative example of aholder and cutting insert in the drilling tool assembly of theinvention.

FIG. 14 is a partial perspective view of an alternative example of aholder in the drilling tool assembly of the invention.

FIG. 15 is a partial perspective view of the example of FIG. 14 with acutting insert mounted in the holder in the drilling tool assembly ofthe invention.

FIG. 16 is a partial perspective view of an alternative example of aholder in the drilling tool assembly of the invention.

DESCRIPTION OF THE INVENTION

Turning now to examples of the invention, it will be noted that thecoolant supply configurations provide distinct advantages in associationwith drilling tools used for hole making. Known coolant configurationsfor drills may include through coolant drills that are designed withcoolant exiting on the clearance surface of the cutting geometry of thedrill. This results in the coolant being directed into the bottom of thedrilled hole. Other arrangements include coolant outlets exiting in thedrill flute and aimed at the bottom of the hole. Such arrangements havea higher potential to disrupt chip flow through the drill flutes, andcoolant is directed toward the bottom of the hole from a distance awayfrom the cutting end of the drill. In the examples of the invention, thearrangement of coolant supply creates a superior coolant trajectory thatbetter targets the entire rake face of the cutting geometry withoutdisrupting chip flow. The examples are directed to improved coolantdelivery systems and methods to enhance drilling performance.

Turning to FIGS. 1-5 , there is illustrated a first example of a drilltool assembly generally indicated at 10. Drill tool assembly 10comprises a holder 12, which has a shank 14 and head portion 16associated therewith. The holder 12 has in general a cylindrical shapewith a first end 20 and second end 22 with the second end 22 and portionof shank 14 adapted to be fixedly attached in a drilling machine foruse. As shown in FIG. 2 , the first end 20 of holder 12 has a clampingor locating slot 30 which may extend across the entire diameter of thehead portion 16 or at least over a center portion thereof at the generallocation of the rotational axis of holder 12. The locating slot 30 has abottom wall 32 positioned in substantially perpendicular orientationrelative to the rotational axis 18 of the holder 12, or this wall 32 maybe angled or comprised of multiple surfaces. Within the locating slot30, at least one cutting insert 50 is precisely positioned with respectto the holder 12 and mates with wall 32. The cutting insert 50 performsthe desired drilling function in conjunction with the holder 12, andallows replacement of the insert 50 when worn. The insert 50 has adouble effective cutting geometry with a point geometry comprising aplurality of cutting edges 56 which are precisely positioned withrespect to the rotational axis of the holder 12 to minimize errors in aresulting drilling operation using assembly 10.

The holder 12 may be configured to include at its first end 20 a pair ofclamping arms 34 and 36 which extend about locating slot 30. Theclamping arms 34 and 36 include apertures 38 which accommodate screws tosecure the cutting insert 50 in its position within the locating slot30. The holes 38 are threaded, and mate with screw holes 52 formed inthe cutting insert 50 to precisely locate the cutting insert 50 in apredetermined location within locating slot 30. Each of the clamp arms34 and 36 also include first and second rake surface coolant supplyvents 40, which are positioned to at least partially overlap the topedge 44 of the upstanding wall 46 of each clamp arm 34 and 36 adjacentthe position of the side of the insert 50 below the rake surface 54associated with each cutting edge 56 in cutting insert 50. A cutting lip55 formed adjacent the cutting edge 56 provides a geometry capable ofproducing a curled metal chip for evacuation. The size and shape of thechip may be controlled by altering the geometry of the cutting lip 55,such as position, size and configuration. The rake surface 54 may beformed to have a planar, concave or curved surface and forms the rakeangle of rake face 54 at the cutting edges 56, which may be uniform orvarying. A notch formed adjacent the rotational axis provides a notchcutting edge and rake surface adjacent the insert tip. The clamp arms 34and 36 may also include angled or curved surfaces which facilitate chipremoval via chip evacuating grooves 37 on each side of the holder 12,corresponding to one of the cutting edges 56. The bottom surface 58 ofthe cutting insert 50 mates with seating surface 32, and although shownto be planar like surface 32, could be of another configurationcorresponding to the shape of bottom surface 32. A locating boss ordowel pin (not shown) may be inserted within an aperture formed in thebottom surface 32 of locating slot 30 in holder 12, which is preciselypositioned with respect to the rotational axis of the holder 12. Thecutting insert 50 includes a locating slot 60 that mates with thelocating boss to precisely position the insert 50 with respect to therotational axis of the holder 12.

The cutting insert 50 may be in the form a spade drill blade, with sideedges 62 of the blade being generally parallel with the rotational axis18 of the holder 12 once the insert 50 is positioned and secured withholder 12. When secured with holder 12, cutting insert 50 will have arotational axis which desirably is coaxial with the rotational axis ofholder 12. The cutting insert 50 has a width, and may include margins 64on edges 62 to facilitate machining of the hole with desired finishcharacteristics. The cutting edges 56 on cutting insert 50 are in theform of an obtuse V-shape, with cutting edges 56 on each side of theaxial center. The cutting edges 56 may include a plurality of cuttingsections, and chip breakers 66, which cooperate to provide the desireddouble effective cutting surface for the material and/or drillingapplication. In general, the insert 50 is designed to cut whenrotationally driven in conjunction with holder 12 in a predetermineddirection, and is not reversible, although such drilling bladeconfigurations are known to those skilled in the art and could be usedin conjunction with the present invention if desired. The mountingapertures 52 which cooperate with the apertures 38 in clamp arms 34 and36 to secure insert 50 within locating slot 30 and seated againstseating surface 32. The locating slot 60 allows positioning of alocating pin therein, and attachment screws (not shown) bias the insert50 and slot 60 against a locating pin for correct and precisepositioning of the insert 50 with respect to holder 12 as desired. Otherarrangements to suitably locate the insert 50 with respect to the holderare contemplated. In this example, the cutting edges 56 aresubstantially parallel to the thickness of insert 50 and sit down fromthe thickness of insert 50 an amount, such as about 0.01 to 0.025 inchesfor example. The dispersion of coolant from coolant holes 40 allows forcoolant to impinge the fusion interface of the chip being formed at andjust away from rake face 54.

In this example, the arrangement of the first and second rake surfacecoolant supply vents 40 allow the application and flow of lubricatingcoolant directly to the rake face 54 adjacent the cutting edges 56 ofthe cutting insert 50, resulting in minimizing undesirable heat,friction, and adhesion to the rake face 54 of machined materials createdby the cutting edges 56 in a tool assembly of this type. This allowshigher penetration rates to be achieved in the drilling operation. Theclamp arms 34 and 36 may optionally include further coolant outlets 48provided on the top surface of the clamp arms 34 and 36 to provideadditional coolant directed at the bottom of the hole to facilitate chipremoval. In the machining operation, the cutting edges 56 deform and cutthe material, generating significant heat and generating chips ofmaterial which must be removed from the rake surface and flushed fromthe hole. The first and second rake surface coolant supply vents 40supply a powerful flow of lubricating coolant directly to the face ofinsert 50 at a position spaced from the rake face 54 adjacent thecutting edges 56 of the cutting insert 50. In this manner, the flow ofcoolant is dispersed into a curtain configuration that then impingesupon the interface between the chip of material being formed and therake face 54. The metal material being plastically deformed by thecutting edges 54, produces mechanical and chemical processes at thefusion boundary of the formed chip which generate the heat. The flow ofthe curtain of coolant provided by the first and second rake surfacecoolant supply vents 40 serves to penetrate the fusion barrier moredirectly by causing flow of coolant onto the fusion boundary from anoffset angle to the rake face and cutting edge interface, in a dispersedmanner from impingement upon the side surface of insert 50 below therake face 54 at 70. The flow of coolant from vents 40 also does notdisrupt the flow of chips into flutes in holder 12 as they are formedand evacuated by the flutes or other areas. The position of vents 40maintain a substantially uniform flow of coolant to the interfacebetween rake face and chip being formed, by the flow of coolant in acurtain across rake face 54 from the offset position adjacent the centerof the insert 50. The dispersal of impinging coolant across the rakeface 54 extends to the outer diameter of the cutting edges 56. Thedistance from rake face 54 of the initial impingement depends on thesize of the insert 50, but is generally spaced a distance of about 0.2to 1 inch, at a position above the centerline of insert 50 height, butmay be any suitable dimension based on the size of the insert 50. Thevents 40 are angled relative to the sides of the insert 50 at an anglebetween 10 and 40 degrees for example, or any suitable angle based onthe size of the insert 50 to produce the dispersion of coolant as shownin FIG. 5 . For some applications, an angle of between 20 and 30 degreeshas been found to be effective. The coolant holes 40 are also angledrelative to the rotational axis of the insert at an angle between 10 and40 degrees for example, with this angle being based on the width of theinsert 50 to allow dispersion of the curtain of coolant from adjacentthe position near the rotational axis of insert 50 and across the entireinterface between the rake face and chip as its being formed duringmachining. For some applications, an angle of between 20 and 30 degreeshas been found to be effective. The size and position of the coolantholes 40 at the interface between the clamp arms 34 and 36 and side ofthe insert 50 also enable the desired volume of coolant to be dispersedover the interface of rake face 54 and the fusion boundary of the formedchip at the cutting edges 56. The coolant may be supplied underpressures of 500 to 1000 psi for example, but other pressures may besuitable or preferred depending on the application and materials beingmachined. Thus, in operation, the chips formed along the cutting edges56 from the center and along the rake face are curled by the cutting lip55 on rake face 54 and chip splitter 66 which introduces stress, whichis then impinged upon by the curtain of coolant supplied by first andsecond coolant vents 40 to shock the material as it is being deformed atthe cutting edges 56 to aid in chip segmentation. The coolant from vents40 fan across the insert face and into the rake face 54 to impinge uponthe fusion boundary of the chip as it is formed, thermally shocking thematerial as the chip is formed at the rake surface interface.

Also in this example, the configuration of the first and second coolantexit holes 40 to have a portion, such as about half the diameter asshown, at the interface of the clamp arms 34 and 36 and the sides of theinsert 50, provides the desired dispersion of coolant along the entirerake face 54 to the outer diameter. The coolant outlets 40 form apartial coolant hole coming out on the slot 30, to direct coolant at therake face and disperse the coolant across the rake face adjacent thecutting edges 56 where the chip of material is formed during machining,and directly at the fusion boundary of the chip being formed. Theconfiguration of coolant holes 40 in combination with the slot 30 andinterface with the side surface of insert 50 to provide partial outletsat the interface, causes turbulence and fringing of coolant out of thepartial orifice to create larger coolant dispersion relative todiameter. This facilitates and creates the desired fan dispersion ofcoolant across the rake face 54. The half hole configuration of thisexample causes fringing left and right when exiting the orifice, and thereduced flow created at the interface causes turbulence at edges toincrease the fringing effect. Though a single coolant outlet 40 providesthe desired dispersion of coolant across the rake face 54, additionalcoolant holes or exits to cover the rake face may be used if desired, orother configurations of the partial outlets 40 may be used rather thanhalf of a circular hole for example.

As will be described with reference to other examples, the insert 50 mayalso have coolant directing structures on the face of the insert to helpdirect flow of coolant to the rake face and forming chip. The flow ofcoolant along the rake face 54 also directly reaches the fusion boundaryof the forming chip on the rake face 54. The curtain of coolant suppliedto the rake face 54 further does not impede movement of chips as theyare formed into the flute for evacuation, but instead helps curl andbreak the chip as it is formed at the rake face and coming off the rakeface. The coolant is directed to this location from the location offsetfrom the flute to flow flat across the face of insert 50 and rake face54, so that formed chips flow over top of the coolant flow to get intothe flute for effective discharge, even with large depth to diameterratios. This arrangement also provides dispersal of coolant to theoutside diameter of the rake face 54, while still getting dispersal atthe center of the tool.

Turning to FIGS. 6-9 , another example of the drilling system 110invention is shown. In this example, the holder 112 may be configuredsimilar to that described in the prior example, but includes additionalstructures at its first end 120. The clamping arms 134 and 136 includefirst and second rake surface coolant supply holes 140 which open intoat least one chamber or pocket 180 formed adjacent the inside surface182 of slot 130. The chamber 180 in this example is configured to have asomewhat triangular shape with the top side intersecting the interfacebetween the side surface 182 and top surface 184 of arms 134 and 136, tocreate a partial opening at the interface. Other suitable shapes ofchamber 180 are contemplated. In this example, the partial openingextends from approximately the center of the clamp arms 134 and 136 at186 to a position adjacent the interior edge of clamp arms 134 and 136at 188. In this manner, the coolant supplied through first and secondrake surface coolant supply holes 140 exits into chamber 180, and thenis dispersed from chamber 180 out the top of the chamber 180 and partialopening formed adjacent the side surface of a cutting insert 150positioned in slot 130. This allows the application and flow oflubricating coolant directly to the rake face 154 and cutting lip 155adjacent the cutting edges 156 of the cutting insert 150. This againresults in minimizing undesirable heat, friction, and adhesion to therake face 154 of machined materials created by the cutting edges 156, toallow higher penetration rates to be achieved. The partial openingformed adjacent the side surface of a cutting insert 150 created bychamber 180 may also include barrier structures 190 for preventing thepossible ingress of material chips in chamber 180 during machiningand/or to facilitate dispersing coolant from chamber 180 to be directedinto the rake face 154 as desired. The structures 190 may have slantedsides to help direct the flow of coolant as desired. Though not shown,additional outlets may be provided on the top surface of the clamp arms134 and 136 to provide additional coolant directed at the bottom of thehole if desired. Again in this example, the first and second rakesurface coolant supply outlets 140 supply a powerful flow of lubricatingcoolant directly to the face of insert 150 at a position spaced from therake face 154 adjacent the cutting edges 156 of the cutting insert 150.In this manner, the flow of coolant is dispersed into a curtainconfiguration that then impinges upon the interface between the chip ofmaterial being formed and the rake face 154. The flow of the curtain ofcoolant provided by the first and second rake surface coolant supplyoutlets 140 in conjunction with chamber 180 serves to disperse coolantmore directly onto the fusion boundary from an offset angle to the rakeface and cutting edge interface, as in the prior example. The flow ofcoolant from the partial openings created by chamber 180 again does notdisrupt the flow of chips into the flutes of holder 112 as they areformed and evacuated by the flutes or other areas. The position of vents140 and chambers 180 maintain a substantially uniform flow of coolant tothe interface between rake face and chip being formed, creating acurtain of coolant across rake face 154 from the offset position fromthe flutes. The dispersal of impinging coolant across the rake face 154extends to the outer diameter of the cutting edges 156. The distancefrom rake face 154 of the initial impingement depends on the size of theinsert 150, but is spaced a distance to allow for desired dispersion ofthe coolant. The outlets 140 are angled relative to the sides of theinsert 150 at an angle to produce the dispersion of coolant as shown inFIG. 9 . In this example, the coolant holes 140 may be substantiallyparallel to the rotational axis of the insert, but chamber 180 thenproduces the dispersion of the coolant at an angle across the entireinterface between the rake face and chip as its being formed duringmachining. Thus, in operation, as in the prior example, the chips formedalong the cutting edges 156 from the center and along the rake face 154are thermally shocked as the material is being deformed at the cuttingedges 156 to aid in chip segmentation.

In another example as shown in FIGS. 10-11 , the holder 212 may beconfigured similar to that described in the prior example, but includesadditional structures at its first end 220. The clamping arms 234 and236 include first and second rake surface coolant supply holes 240 whichopen onto the inside surface 282 of slot 230. The outlets 240 exit intoa chamber or pocket 280 formed on side surface of insert 250 in thisexample. The chamber 280 is configured to have a somewhat triangularshape with the top side opening into the top of insert 250, whichintersects the interface between the side surface 282 and top surface284 of arms 234 and 236, to create a partial opening at the interface.Other suitable shapes of chamber 280 are contemplated. In this example,the partial opening extends from approximately the center of the clamparms 234 and 236 at 286 to a position adjacent the interior edge ofclamp arms 234 and 236 at 288. In this manner, the coolant suppliedthrough first and second rake surface coolant supply holes 240 exitsinto chamber 280, and then is dispersed from chamber 280 out the top ofthe chamber 280 and partial opening formed adjacent the side surface ofa cutting insert 250 positioned in slot 230. This allows the applicationand flow of lubricating coolant directly to the rake face 254 andcutting lip 255 adjacent the cutting edges 256 of the cutting insert250. This again results in minimizing undesirable heat, friction, andadhesion to the rake face 254 of machined materials created by thecutting edges 256, to allow higher penetration rates to be achieved.There may also be coolant flow diverting structures 290 formed adjacentthe partial opening between the side surface of a cutting insert 250created by chamber 280, to control flow of and dispersion of coolantacross the entire rake face 254. The structures 290 may be upstandingoff of the side surface of insert 250 and tapering down toward the rakeface 254, but other suitable configurations, such as curved members orgrooves may be used to control flow of coolant if desired. In theconfiguration shown, or other suitable configurations of structures 290,the structures 290 also serve as chip breakers, to facilitate theformation of chips as the material is curled by the cutting lip 255 andrake face 254. The replaceable cutting tip 250 is responsible forshearing material from the workpiece and chip-splitters create two ormore chips formed along the rake face 254 further broken or segmented bythe structures 290 serving as chip breakers. The chip breakers 290 curlthe chip, introducing stress, ultimately aiding in chip segmentation.The coolant delivery system provides a coolant cavity 280, which helpsfan and disperse the coolant to hit all cutting edges of the cutting tip250. To further help with coolant distribution and aid chip formation,the structures 290 which serve as further chip breaker ridges also allowdirecting coolant directly into the chip breaking zone via coolantchannels 292 formed between ridges 290. While other tools delivercoolant parallel to the tool axis, supplying coolant to the cutting tipby flooding the hole created by the tool, the purpose of this and otherdesigns of the invention provide the ability to fan the coolant acrossthe face of the insert, delivering it to the entire cutting edge.

Though not shown, additional outlets may be provided on the top surfaceof the clamp arms 234 and 236 to provide additional coolant directed atthe bottom of the hole if desired. Again in this example, the first andsecond rake surface coolant supply outlets 240 supply a powerful flow oflubricating coolant directly to the chamber 280 formed in the face ofinsert 150 at a position spaced from the rake face 254. In this manner,the flow of coolant is dispersed into a curtain configuration that thenimpinges upon the interface between the chip of material being formedand the rake face 254. The flow of the curtain of coolant provided bythe first and second rake surface coolant supply outlets 240 inconjunction with chamber 280 serves to disperse coolant more directlyonto the fusion boundary from an offset angle to the rake face andcutting edge interface, as in the prior examples. The flow of coolantfrom the partial opening created by chamber 280 again does not disruptthe flow of chips into the flutes of holder 212 as they are formed andevacuated by the flutes or other areas. The position of vents 240 andchambers 280 maintain a substantially uniform flow of coolant to theinterface between rake face and chip being formed, creating a curtain ofcoolant across rake face 254 from the offset position from the flutes.The dispersal of impinging coolant across the rake face 254 extends tothe outer diameter of the cutting edges 256. The distance from rake face254 of the initial impingement depends on the size of the insert 250,but is spaced a distance to allow for desired dispersion of the coolant.The outlets 240 are angled relative to the sides of the insert 250 at anangle to produce the dispersion of coolant as desired. In this example,the coolant holes 240 may be substantially parallel or angled to therotational axis of the insert 250, which in conjunction with chamber 280then produces the dispersion of the coolant as desired. Thus, inoperation, as in the prior examples, the chips formed along the cuttingedges 256 from the center and along the rake face 254 are thermallyshocked as the material is being deformed at the cutting edges 256 toaid in chip segmentation.

A further example is shown in FIGS. 12-13 , with system 310 includingholder 312 that includes additional structures at its first end 320. Theclamping arms 334 and 336 include first and second rake surface coolantsupply holes 340 which open onto the inside surface 382 of slot 330. Theoutlets 340 exit into a chamber or pocket 380 formed on side surface ofinsert 350 in this example. The chamber 380 is configured to have asomewhat triangular shape with the top side opening toward the top ofinsert 350, which intersects the interface between the side surface 382and top surface 384 of arms 334 and 336, to create a partial opening atthe interface. The opening is wide and thin to cause dispersion of thecoolant in a curtain as desired while preventing the ingress of chips ordebris. Other suitable shapes of chamber 380 are contemplated. In thisexample, the partial opening extends from approximately the center ofthe clamp arms 334 and 336 at 386 to a position adjacent the interioredge of clamp arms 334 and 336 at 388. In this manner, the coolantsupplied through first and second rake surface coolant supply holes 340exits into chamber 380, and then is dispersed from chamber 380 out thetop of the chamber and partial opening formed adjacent the side surfaceof a cutting insert 350. This allows the application and flow oflubricating coolant directly to the rake face 354 adjacent the cuttingedges 356 of the cutting insert 350. In this example, the cutting edges356 extend outwardly from the thickness of the insert body, and the flowof coolant directly impinges on the rake surface 354 and interface withthe cutting edges 356 to shock and facilitate chip formation. This againresults in minimizing undesirable heat, friction, and adhesion to therake face 354 of machined materials created by the cutting edges 356, toallow higher penetration rates to be achieved. There may also be coolantflow diverting structures 390 on the side of insert 350 to facilitatedirecting flow of coolant across the entire rake face if desired, and/orin the chamber 380. The structures 390 may be one or more grooves in theside surface of insert 350, or other suitable configurations, to controlflow of coolant if desired. Additional coolant holes on the top of clamparms 334 and 336 may be used if desired. The partial opening between theside surface of a cutting insert 350 created by chamber 380, controlsthe flow of and dispersion of coolant across the entire rake face 354.

Turning to FIGS. 14-15 , with the holder 412 that includes additionalstructures at its first end 420. The clamping arms 434 and 436 includefirst and second rake surface coolant supply holes 440 which open ontothe inside surface 482 of slot 430. The outlets 440 exit into a chamberor pocket 480 machined into the side surface of clamp arms 440 adjacentthe centerline of the tool for example. The chamber 480 is configured tohave a somewhat triangular shape with the top side opening toward thetop of clamp arms 434 and 436, which intersects the interface betweenthe side surface 482 and top surface 484 of arms 434 and 436, to createa partial opening at the interface. The opening is wide and thin tocause dispersion of the coolant in a curtain as desired while preventingthe ingress of chips or debris. Other suitable shapes of chamber 480 arecontemplated. In this example, the partial opening extends fromapproximately the center of the clamp arms 434 and 436 to a positionadjacent the interior edge of clamp arms 434 and 436. In this manner,the coolant supplied through first and second rake surface coolantsupply holes 440 exits into chamber 480, and then is dispersed fromchamber 480 out the top of the chamber and partial opening formedadjacent the side surface of a cutting insert mounted in slot 430. Thisallows the application and flow of lubricating coolant directly to therake face adjacent the cutting edges of the cutting insert. There mayalso be coolant flow diverting structures formed on the side of thecutting insert to facilitate directing flow of coolant across the entirerake face if desired, and/or in the chamber 480. Additional coolantholes on the top of clamp arms 434 and 436 may be used if desired. Thepartial opening between the side surface of a cutting insert created bychamber 480, controls the flow of and dispersion of coolant across theentire rake face of a cutting insert.

Turning to FIG. 16 , with the holder 512 that includes additionalstructures at its first end. The clamping arms 534 and 536 include firstand second rake surface coolant supply holes 540 which open onto theinside surface 582 of slot 530. The outlets 540 exit into a chamber orpocket 580 formed by additive manufacturing techniques in associationwith the coolant channel and outlet 540, formed into the holder 512 andinterior side portion of the clamp arms 534 and 536 for example. Thechamber 580 and outlet 540 are configured to direct coolant out of thechamber 580 in a dispersed pattern to the entire rake face of a cuttinginsert positioned in slot 530. The top of chamber 580 opens toward thetop of clamp arms 534 and 536, which intersects the interface betweenthe side surface 582 and top surface 584 of arms 534 and 536, to createa partial opening at the interface. The opening is directed and thin tocause dispersion of the coolant in a curtain as desired while preventingthe ingress of chips or debris. Other suitable shapes of chamber 580 arecontemplated. The additive manufacturing or molding techniques allow theoutlet 540 to be directed in a manner to be dispersed along the entirerake face of a cutting edge as desired. Other coolant flow divertingstructures formed in association with outlet 540 or chamber 580 may beused and/or on an insert positioned in holder 512. Additional coolantholes on the top of clamp arms 534 and 536 may be used if desired. Thedirected outlet 540 and partial opening between the side surface of acutting insert created by chamber 580, controls the flow of anddispersion of coolant across the entire rake face of a cutting insert asdesired.

The terms “comprising,” “including,” and “having,” as used in the claimsand specification herein, shall be considered as indicating an opengroup that may include other elements not specified. The terms “a,”“an,” and the singular form of words shall be taken to include theplural form of the same words, such that the terms mean that one or moreof something is provided. The terms “at least one” and “one or more” areused interchangeably. The term “single” shall be used to indicate thatone and only one of something is intended. Similarly, other specificinteger values, such as “two,” are used when a specific number of thingsare intended. The terms “preferably,” “preferred,” “prefer,”“optionally,” “may,” and similar terms are used to indicate that anitem, condition or step being referred to is an optional (i.e., notrequired) feature of the embodiments.

While this invention has been described with reference to embodimentsthereof, it shall be understood that such description is by way ofillustration only and should not be construed as limiting the scope ofthe claimed embodiments. Accordingly, the scope and content of theembodiments are to be defined only by the terms of the following claims.Furthermore, it is understood that the features of any embodimentdiscussed herein may be combined with one or more features of any one ormore embodiments otherwise discussed or contemplated herein unlessotherwise stated.

What is claimed is:
 1. A drilling system comprising, a holder having arotational axis and first and second clamp arms with side surfacesforming a mounting slot, a cutting insert with sides positioned adjacentthe side surfaces of the mounting slot and cutting edges extending fromthe rotational axis of the cutting insert and rake surfaces adjacent thecutting edges, the cutting edges spaced from the top of the first andsecond clamp arms when the insert is mounted in the mounting slot,wherein the holder comprises at least one coolant channel disposedthrough the first and second clamp arms with the at least one coolantchannel oriented at an angle to one of the sides of the insert andhaving an outlet positioned below the rake surfaces of the insert,wherein liquid coolant supplied to the at least one coolant channelexits the outlet and is dispersed in curtain across the entire rake faceof each cutting edge after the liquid coolant impinges on the side ofthe insert from the at least one coolant channel.
 2. The drilling systemof claim 1, wherein the outlet of the at least one coolant channel isformed at the interface between the sides of the mounting slot and sidesof the insert, to cause turbulence and fringing of liquid coolant out ofthe outlet to create larger dispersion of the liquid coolant.
 3. Thedrilling system of claim 1, wherein the outlet of the at least onecoolant channel is formed to cause fringing left and right of the liquidcoolant when exiting the at least one coolant outlet.
 4. The drillingsystem of claim 1, wherein the outlet of the at least one coolantchannel is formed as a non-circular outlet that causes fringing left andright of the liquid coolant when exiting the at least one coolantoutlet.
 5. The drilling system of claim 1, wherein the liquid coolanthas reduced flow rate upon impinging the side of the insert that causesturbulence at edges of the outlet of the at least one coolant channel toincrease fringing left and right of liquid coolant when exiting the atleast one coolant outlet.
 6. The drilling system of claim 1, wherein theoutlet of the at least one coolant channel is positioned to disperseliquid coolant toward a chip as it is formed at the cutting edge at thetop of the rake surface to promote chip segmentation through thermalshocking of the chip at the rake surface by the directed liquid coolant.7. The drilling system of claim 1, wherein the outlet of the at leastone coolant channel is formed to disperse liquid coolant toward a chipas it is formed at the cutting edge at the top of the rake surface toprovide lubricity and coolant flow around the area adjacent the cuttingedge, minimizing re-cutting of chips and causing evacuation of chipsfrom the rake surface adjacent the cutting edge after segmentation of achip during cutting.
 8. The drilling system of claim 1, wherein theoutlet of the at least one coolant channel disperses liquid to impingethe fusion interface of the chip being formed at and just away from acutting lip adjacent the cutting edge on the rake surface.
 9. Thedrilling system of claim 1, wherein the cutting edges are at apredetermined spaced distance from the outlets of the at least onecoolant channel on each side of the insert.
 10. The drilling system ofclaim 1, wherein the coolant channel in each of the first and secondclamp arms are supplied by at least one coolant supply channel formedthrough the holder, and the at least one coolant supply channel has alarger diameter than the at least one coolant channel in each of thefirst and second clamp arms such that the velocity of the liquid coolantincreases as it is supplied to the at least one coolant channel in eachof the first and second clamp arms.
 11. A drilling system comprising aholder having a rotational axis, a cutting insert attachable to theholder with cutting edges extending from the rotational axis at the topof the insert when attached to the holder, wherein the holder comprisesat least one coolant channel extending toward each side of the insertwith an outlet positioned to direct coolant at each of the sides of theinsert at a position spaced from the cutting edges, wherein the coolantspreads on the side of the insert to impinge upon the interface betweenthe chip of material being formed along the length of the cutting edge.12. The drilling system of claim 11, wherein the outlet of the at leastone coolant channel is formed to disperse liquid coolant toward a chipas it is formed to minimize the re-cutting of chips and causingevacuation of chips from the cutting edge after segmentation of a chipduring cutting.
 13. The drilling system of claim 11, wherein the coolantsupply channels are dimensioned to supply a predetermined volume ofliquid coolant and directed to disperse the volume of liquid coolantagainst the side of the insert at an angle to create the curtain ofcoolant.
 14. The drilling system of claim 11, wherein flow of coolantfrom the at least one coolant supply channel is directed from an offsetposition relative to the cutting edge to promote and not disrupt theflow of chips from the cutting edges into flutes in the holder afterthey are formed.
 15. The drilling system of claim 11, wherein the atleast one coolant channel for each side of the insert have outletsdisperse the coolant directly onto the fusion boundary of a formed chipfrom an offset angle to the cutting edge.
 16. The drilling system ofclaim 11, wherein the outlet of the at least one coolant channel isformed to cause fringing left and right of the coolant when exiting theoutlet.
 17. The drilling system of claim 11, wherein the outlet of theat least one coolant channel intersects the top of the side surfaces ofthe mounting slot.
 18. The drilling system of claim 11, wherein theposition of the initial impingement of coolant on the sides of theinsert from the outlets of the coolant channels is a distance from about0.2 to 1 inch from a rake face formed adjacent each cutting edge.
 19. Adrilling system comprising a holder having a rotational axis and chipevacuation flutes, a cutting insert with cutting edges extending from arotational axis of the insert and rake faces adjacent the cutting edges,wherein the holder comprises at least one coolant channel to each sideof the insert when mounted with the holder, with the at least onecoolant channel having an outlet positioned to direct coolant at each ofthe sides of the insert below the cutting edges from a position offsetfrom the flute formed in the holder to flow substantially flat acrossthe face of insert to the cutting edge on each side of the insert, sothat formed chips during cutting flow over top of the coolant flow andinto the flute for effective discharge.
 20. The drilling system of claim19, wherein the outlet of the at least one coolant channel is positionedadjacent the flute associated with each cutting edge at a predeterminedspacing from the cutting edge.